Manual edited by: Robert M. Woods and James A. …

1 Version The information set forth herein is based on technical data that Zaclon believes to be reliable. It is intended for use by persons having technical skill and at their own discretion and risk. Since conditions of use are outside our control, we make no warranties, expressed or implied, and assume no liability in connection with any use of this information. Nothing herein is to be taken as a license to operate under or a recommendation to infringe any patents. Zaclon grants a license to install and use this software on one computer at a time. This galvanizing Handbook (Software Edition) may not be copied or redistributed, but sections of the Handbook may be printed and used freely within the customer's organization.

2 All text and program code is copyrighted 1996 by Zaclon edited by: Robert M. Woods and James A. ColeEdition Date: September, 1996 2981 Independence RoadCleveland, Ohio 44115(216) 271-1601 Table of Contents IndexINDEXThe index is one way to access Zaclon's galvanizing Handbook via a browser. (You can also use the table of contents, or go directly to a section.) Look through the entire index by clicking on the Windows scrollbar arrow to the bottom right to find the topic you want, or take a shortcut directly to a section of the index by clicking on one of the letters of the alphabet represented by the icons you find the topic in which you are interested, click on the topic name to go there. Table of Contentsacid cleaningacid, choice ofair pollutionacid recoveryalkaline cleaning bathsalloy layer too thickalloy steelsaluminumaluminum, insufficient in zincammonium chlorideHow to use this Manual : Click on words highlighted in RED or PURPLE to go that section of the handbook.

3 Some icons are also clickable ( , the graph icon can be clicked in various places throughout the handbook to display a table or figure). Places you have visited should be highlighted in PURPLE. Your system may display different colors, if your browser is set up to override custom colors or if your computer has limited color capabilites. If a section you are viewing is longer than your screen, please click on the Windows scrollbar arrow on the bottom right to see the rest of the section. Recommended browsers include Netscape or later versions, and Microsoft Internet Explorer or later versions. antimonyASTM specifications Go to top Table of Contents Baum to density conversionbismuth cadmiumchromatingchromating, health concernscleaning baths, disposalconversion coatingcoppercorrosioncorrosion, preventioncorrosion prevention, chromating Go to top Table of Contentsdata sheets, Zaclondensity conversionsderustingdescalingdrossdross, minimizing environmental considerations Go to top Table of Contentsfinishingfinishing, quenchingfinishing, vibratorflux blanketflux concentration, measuringflux, kettle (See additional index entries under kettle flux.)

4 Flux ratioflux, ratio, definition offlux reactionsldross formation liron oxide removal lskimmings lwith base steel lwith Zinc flux, purificationFlux Selection Guideflux skimmingsflux solutions, controlflux, start upflux, swapping outflux, top (See additional index entries under kettle flux.)fluxes, general purpose fluxes, intermediate activity, description offluxes, high activity, description offluxes, high activityfluxes, low acitivity (minimal fuming), description offluxes, minimal fumingfluxes, specialtyfumesfumes, minimizingfumes, wet galvanizing Go to top Table of Contents galvanizing coating defects and solutionslpoor adhesion ldull gray coatings lrough coatings luneven and lumpy coatings lblisters luncoated areas lflux spots/flux inclusions lwhite rust galvanizing , comparison of wet vs.

5 Drygalvanizing, drygalvanizing, general galvanizing , high temperaturegalvanizing, low temperaturegalvanizing process problems and solutionslexcessive smoking lexcessive dross formation galvanizing , wetgalvanizing, wet: cleaninggalvanizing, wet: prefluxinggalvanizing, wet: rinsinggalvanizing, wet: surface preparationgalvanizing, wet with minimal fumes Go to top Table of Contentshigh temperature galvanizationhydrochloric acid improving profitabilityiron contaminationiron contamination, costsiron contamination, test Go to top Table of Contentskettle fluxkettle flux, ammonium chloridekettle flux, zinc chloridekettle, sizingkettle, starting upkettle temperature leadlead, wetting of substratelow temperature galvanizing Go to top Table of Contentsmechanical surface preparation (Also see index entires under surface finishing methods, mechanical)

6 Metal cleanersmetal cleaners, buildersmetal cleaning formulationmetal silicatesminimal fume fluxes nickel Go to top Table of Contentsphase diagram, flux systemspicklingpickling acid, action ofpickling acid concentrationpickling bath, agitationpickling bath, iron concentrationpickling bath, temperaturepickling, control testspickling, inhibitor choicepickling procedurepickling rateplant layoutPolygalvapollution, airpollution, waterpreflux, choosingpreflux concentrationpreflux contaminantspreflux equipmentpreflux, high concentrationpreflux, iron contamination inpreflux, preparationpreflux, temperatureprefluxed parts, drying and heatingprofitabiltiy, improving Go to top Table of Contentsquenching reactive steel, processing methodsrecyclingrinsing, after alkaline cleaningrinsing, after picklingrinsing, chemical surface preparationrusting rate Go to top Table of Contentssiliconsizing the kettleskimmingssulfate contamination, measuringsulfate control flux (Also see ZACLON Sulfate Control index entry.)

7 Sulfuric acidsurface finishing methods, mechanical labrasive blasting lbarrel finishing lbrush and hand finishing lgrinding and polishing lvibratory finishingsurface preparationlchemical lmechanical lmethod selection surface soilssteels, alloysteels, high siliconsteels, phosphoroussteels, reactivesteels, reative: processingsteels, Sandolin Go to top Table of Contentstanks, alkaline cleaningTechnigalvatintop fluxtop flux acitivity, maintainingtop flux additionstop flux blankettop flux, choosingtop flux foaming agentstop flux viscositytrouble shooting uncoated areasuneven and lumpy coatings Go to top Table of Contents waste acid disposalwater pollutionwet vs. dry galvanizingwetting agentswetting agents, chemical surface preparationwhite rustwhite rust prevention Go to top Table of Contents Zaclean ConcentrateZACLON 2 NZACLON AZACLON ABZACLON AFZACLON CZACLON CSZACLON Ammonium ChlorideZACLON FZaclon Flux Selection GuideZaclon Inc.

8 , corporate address and phone numberZACLON KZACLON Start Up FluxZACLON Sulfate ControlZACLON WZACLON WRPZACLON WRP applicationzinc ashzinc bath temperaturezinc carbonatezinc coating, uniformityzinc determinationzinc, Eta layerzinc hydroxidezinc losszinc nickel coatingzinc oxide Go to Top Table of ContentsTABLE OF CONTENTSThe table of contents is one way to access Zaclon's galvanizing Handbook via a browser. (You can also use the index or go directly to a section.) Look through the entire table of contents by clicking on the Windows scrollbar arrow to the bottom right to find the section you want, or take a shortcut directly to a section of the table of contents by clicking on one of the section headings you find the section or subsection of the Manual in which you are interested, click on the section or subsection name to go there.

9 Index SECTION 1: INTRODUCTION GENERAL DESCRIPTION OF ZACLON galvanizing FLUXES GENERAL PURPOSE FLUXES ZACLON F ZACLON K ZACLON CS ZACLON C TOP FLUX MAINTENANCE/HIGH ACTIVITY FLUX ZACLON 2N AMMONIUM CHLORIDE START-UP FLUXHow to use this Manual : Click on words highlighted in RED or PURPLE to go that section of the handbook. Some icons are also clickable ( , the graph icon can be clicked in various places throughout the handbook to display a table or figure). Places you have visited should be highlighted in PURPLE. Your system may display different colors, if your browser is set up to override custom colors or if your computer has limited color capabilites. If a section you are viewing is longer than your screen, please click on the Windows scrollbar arrow on the bottom right to see the rest of the section.

10 Recommended browsers include Netscape or later versions, and Microsoft Internet Explorer or later versions. Section 1: Introduction Section 6: Troubleshooting Section 2: Surface Preparation Section 7: Environmental Considerations Section 3: Fluxing Section 8: Company and Product Information Section 4: galvanizing Section 9: Appendices Section 5: Finishing and Post-treatments ZACLON START UP FLUX MINIMAL FUMING FLUXES ZACLON AF ZACLON A ZACLON AB SPECIALTY FLUXES ZACLON W ZACLON SULFATE CONTROL OTHER INFORMATION Go to top IndexSECTION 2: SURFACE PREPARATION BASIC INFORMATION PART 1: MECHANICAL SURFACE PREPARATION GENERAL INFORMATION ABRASIVE BLASTING BARREL AND VIBRATORY FINISHING BRUSH AND HAND FINISHING GRINDING AND POLISHING PART 2.